Footwear with improved upper

ABSTRACT

An article of footwear including a sole assembly and an upper, the upper including a flexible envelope, the boot extending lengthwise from a rear end to a front end, widthwise between a lateral side and a medial side, and height-wise from the sole assembly to an upper end, the boot including a stiffener located in the area of the rear end. The boot includes a reinforcement which is at least partially superimposed onto the stiffener.

CROSS-REFERENCE TO RELATED APPLICATION

This application is based upon French patent application Ser. No. 11/01775, filed Jun. 9, 2011, the disclosure of which is hereby incorporated by reference thereto in its entirety, and the priority of which is claimed under 35 U.S.C. §119.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to footwear, especially sports footwear, and more particularly a boot used in fields such as cross-country or telemark skiing, walking or running on flat or mountainous terrain, snowboarding, snowshoeing, roller skating, skateboarding, cycling, a ball sport, and the like.

2. Background Information

For a given application, an article of footwear, or boot, typically includes an outer sole assembly and an upper, the upper including a flexible envelope. This provides a certain freedom of movement of the foot in relation to the lower leg of a user, thus enabling the user to practice the sporting activity. It is obviously desirable that a boot be adapted to the user. This means that the boot should have characteristics related to the user, especially to his level of skill in a respective sport, style of practice, weight, and/or the like.

In cross-country skiing, for example, a particular skiing technique used can be considered, namely, the classic technique of alternate steps, with the skis parallel, or the technique of skate-skiing, or skating steps, with the skis oriented laterally with respect to the direction of movement of the skier. The flexibility required for the upper of the boot is not the same depending upon whether the steering style involves alternate steps or skating steps. Moreover, for each type of skiing technique, various users often have various skills and various weights. Consequently, although a pair of boots is selected to best meet the needs of the user, it may be adequately, but not completely, suited to the user.

More specifically, it is known in the field of cross-country skiing to make flexible boot uppers that are suitable for classic skiing and boots that are suitable for skate-skiing.

For skiing with the alternate steps, a flexible boot upper is provided with a low heel stiffener, located in the area of the rear end and adapted to hold the heel of the foot in the upper, in particular transversely. The stiffener extends around the heel of the foot, beneath the ankle joint. The boot is well-suited to classic skiing, as it allows for free, or relatively free, bending of the lower leg. However, for this skiing style, a boot is not completely satisfactory for certain users, for the aforementioned reasons. Thus, a user sometimes cannot transmit all of the energy related to the thrusts, or does not perceive all of the sensory information coming from the skis. In other words, although generally good, the energy efficiency associated with the steering is not optimal.

With respect to skate-skiing, a flexible boot upper is provided with a high heel stiffener, located in the area of the rear end and adapted to hold not only the heel of the foot in the upper, in particular transversely, but also the ankle itself, or even the lower part of the lower leg, in particular transversely. Thus, the stiffener extends around the heel of the foot, beneath the ankle joint, and extends up to, or above, the ankle, on the lateral side and/or medial side of the boot. This extension provides a transverse support to the ankle, or even the lower leg, for transmitting steering thrusts in the transverse direction. The boot is therefore suitable for skate-skiing. However, in this case also, for this skiing style, a boot is not completely satisfactory for certain users. Sometimes, a user cannot transmit all of the energy related to the thrusts, or does not perceive all of the sensory information coming from the skis. The energy efficiency associated with the steering is not optimal.

Furthermore, the stiffener may be a source of discomfort, in the sense that it interferes with the transmission of the steering thrusts or the passage of sensory information.

SUMMARY

In view of the preceding, the invention generally seeks to improve a boot comprising an outer sole assembly, an upper provided with a flexible envelope, and a heel stiffener located in the area of the rear end.

The invention enables a boot to be selected for a user to be one that suits the user best, by taking into account the user's skill level, style of practice, weight, and/or the like.

In addition, the invention enables the user to optimize his/her use efficiency. In the case of cross-country skiing, the boot must optimize the transmission of energy related to the steering thrusts, or accurately restore the sensory information coming from the ski. This is actually about optimizing steering efficiency.

Further, the invention reduces, or completely eliminates, any hindrance or discomfort that may occur while skiing.

Still further, the invention reduces manufacturing costs of a boot.

To these ends, the invention provides a boot including a sole assembly and an upper, the upper including a flexible envelope, the boot extending lengthwise from a rear end to a front end, widthwise between a lateral side and a medial side, and height-wise from the sole assembly to an upper end, the boot including a stiffener located in the area of the rear end.

The boot according to the invention includes a reinforcement which is at least partially superimposed onto the stiffener.

The reinforcement modifies the physical or mechanical properties of the upper in the area in which it extends. If the reinforcement extends only in the area of the stiffener, then the properties of the upper are adjusted only in the area of the stiffener. If the reinforcement extends in the areas of both the stiffener and a portion of the upper contiguous to the stiffener, then the physical or mechanical properties of the upper are modified in the area of the stiffener and also in the area of the contiguous portion of the upper. This portion, located between the stiffener and the upper end, is adjacent to the stiffener.

The reinforcement is made of one or more materials adapted to provide the upper with the desired properties, in the area in which it is positioned. By way of example, the reinforcement includes a synthetic material, such as plastic. The reinforcement is made as a function of the characteristics desired for the boot, based on a user profile. In other words, the reinforcement is provided so that the boot has characteristics related to the user, especially his/her skill level, style of practice, weight, and/or the like.

This allows for better transmission of energy related to steering thrusts, as well as better perception of sensory information. In other words, the transmission or perception efficiency is improved.

Advantageously, the result is that a boot selected for a user is more suitable to that user. It means that the boot is defined by its physical and mechanical characteristics. Indeed, the reinforcement has made it possible to take into account the user's level or style of practice, as well as his/her weight, and/or the like.

Another advantage provided by the boot of the invention is a better use efficiency. User fatigue is reduced because the user exerts less energy for a given thrust intensity. The steering of the ski is more precise because the user better perceives the sensory information.

Another advantage is increased comfort. Indeed, the adjustment of the characteristics of the upper, by positioning the reinforcement, better adapts the boot to the needs of the user.

Another advantage is related to the method for manufacturing the boot according to the invention. Indeed, it is possible to make different boots, that is to say boots having different physical or mechanical properties in the area of the stiffener, either by choosing not to use a reinforcement, or by using a reinforcement. In the latter case, it is possible, during manufacture, to select a given reinforcement from a series of several, in order to get a boot with the desired characteristics. The gain comes from the fact that it is less expensive to make different reinforcements, provided to cooperate with a given stiffener, which is common to all boots, than to make different stiffeners for different types of boots.

The invention also relates to a method for manufacturing a boot comprising a sole assembly and an upper, the upper including a flexible envelope, the boot including a stiffener.

The manufacturing method according to the invention provides a reference step of molding the stiffener using a mold having a base with a shape that demarcates the inner surface of the stiffener, as well as a first cover which demarcates the outer surface of the stiffener. In addition, the method includes a step following the reference step of molding a reinforcement in contact with the stiffener, using a mold which includes the base carrying the stiffener, as well as a second cover substituted for the first, the second cover leaving space to add the reinforcement.

BRIEF DESCRIPTION OF DRAWINGS

Other characteristics and advantages of the invention will be better understood from the following description, with reference to the annexed drawings showing, by way of a non-limiting embodiment, how the invention can be embodied, and in which:

FIG. 1 is a side view of a boot according to the invention, in a configuration in which the reinforcement is not positioned;

FIG. 2 is a rear perspective view of the stiffener of the boot, isolated from the boot;

FIG. 3 is a top view of the stiffener of FIG. 2;

FIG. 4 is a rear perspective view of the stiffener and of the reinforcement, prior to one being affixed to the other;

FIG. 5 is a rear perspective view of the stiffener and of the reinforcement, one being affixed to the other;

FIG. 6 is a rear perspective view related to the positioning of a collar on the reinforcement; and

FIG. 7 is a side view of the boot, in a configuration in which the reinforcement and the collar are positioned.

DETAILED DESCRIPTION

The exemplary embodiment of the invention described hereinafter more specifically relates to boots intended for the practice cross-country or telemark skiing. However, the invention applies to other fields, such as those mentioned above.

The proposed embodiment is described with reference to FIGS. 1 to 7.

As shown in FIG. 1, for example, a cross-country ski boot 1 is adapted to receive the foot of the user.

As known, the boot 1 includes an outer sole assembly 2 and an upper 3, which includes a flexible envelope 4. The envelope 4 is capable of becoming deformed, for example flexionally, to follow the movements of the foot in relation to the lower leg, particularly in the case of front or rear flexing, or transverse inclination. The boot 1 extends lengthwise from a rear end, or heel 5, to a front end, or tip 6; widthwise between a lateral side 7 and a medial side 8; and height-wise from the outer sole assembly 2 to a upper end 9.

As shown, the upper 3 includes a lower portion 11, provided to cover the foot, and an upper portion 12, provided to surround the ankle and, possibly, a portion of the lower leg.

According to the illustrated embodiment, the flexible envelope 4 is an outer portion of the upper 3, which thus demarcates an outer surface 13 of the boot. This does not prevent the upper 3 from being provided with other portions, not shown, such as an inner envelope, one or more devices for reversibly tightening one or all of the envelopes, or the like.

As can be seen, not only in FIG. 1, but also in FIGS. 2 and 3, the boot 1 includes a heel stiffener 15 located in the area of the rear end 5 of the boot. The stiffener 15 itself includes a lateral base 16 and a lateral wall 17, a rear base 18 and a rear wall 19, as well as a medial base 20 and a medial wall 21.

Each base 16, 18, 20 is oriented parallel to the outer sole assembly 2 and arranged at the junction of the sole assembly and the flexible envelope 4. It could alternatively be provided to insert the bases 16, 18, 20 between two layers of the sole assembly 2. In any case, the bases 16, 18, 20 extend within the structure of the boot. The walls 17, 19 and 21 cover the flexible envelope 4 in the region of the rear end 5. This provides the envelope with the local rigidity needed to hold the heel of the foot, particularly along a transverse direction of the boot. This direction extends from the lateral side 7 to the medial side 8.

Without being limiting, the lateral 17, rear 19, and medial 21 walls extend one another to form a continuous portion in the area of the upper 3. It is this portion that covers the flexible envelope 4. More broadly, the lateral 17, rear 19, and medial 21 walls, as well as the lateral 16, rear 18, and medial 20 bases, together form a unitary element, i.e., a one-piece element. This facilitates the manufacture of the stiffener 15, and its positioning in the structure of the boot. The stiffener 15 is for example comprised of a molded synthetic material, such as polyurethane, polyamide, or any equivalent material.

The lateral wall 17 extends longitudinally from the rear wall 19 to a front end 25, and height-wise from the lateral base 16 to a top 26. Similarly, the medial wall 21 extends longitudinally from the rear wall 19 to a front end 27, and height-wise from the medial base 20 to a top 28. Consequently, the rear wall 19 extends widthwise from the lateral wall 17 to the medial wall 21, and height-wise from the rear base 18 to a top 30. The tops 26, 28, 30 of the walls 17, 21, 19 are located at a distance from the sole assembly 2, such that they are opposite the heel of the foot, slightly below the ankle. This provides the upper 3 with great freedom of flexion. In other words, the forward or backward flexion of the lower leg and the lateral inclinations are facilitated. This boot structure is well-suited to skiing using the technique of alternate steps, i.e., classic skiing.

According to the invention, as can be understood from FIGS. 4-7, the boot 1 includes a reinforcement 33 which is at least partially superimposed onto the stiffener 15. The reinforcement 33 modifies the physical or mechanical properties of the upper in the area in which it extends, that is to say, either in the area of the stiffener 15 alone, or in the area of the stiffener and a portion of the flexible envelope 4. In any case, the reinforcement 33 partially covers the stiffener 15. It is possible to select the constituent material of the reinforcement 33 to adjust, i.e., to reduce, the flexion of the upper 3. It is also possible to choose the extent of reinforcement to select subdivisions of the upper whose ability to flex must be reduced. In the end, depending upon the choices made, a boot is more capable of meeting the specific needs of a user. For example, a line of boots available in stores can be expanded, thereby facilitating the selection of a pair of boots.

The reinforcement 33 is for example comprised of a molded synthetic material, such as polyurethane, polyamide, or any equivalent material. This facilitates its integration with the remainder of the boot, as can be understood better hereinafter.

According to the described non-limiting embodiment, the reinforcement 33 includes an arch 35 which extends along the lateral side 7, the rear end 5, and the medial side 8 of the boot 1, in the area of an upper end 36 of the stiffener 15. This end 36 actually includes at least a portion of the tops 26, 28, 30 of the lateral 17, medial 21, and rear 19 walls. The arch 35 extends partially strictly opposite the stiffener 15, and partially strictly opposite the flexible envelope 4. It can be said that the reinforcement 33 extends towards the upper end 9 of the boot 1, beyond the upper end 36 of the stiffener. Therefore, the arch 35 stiffens both the stiffener 15 and the envelope 4, in the area of the rear end 5 of the boot 1. The heel of the foot is thus held more firmly, especially in the transverse direction. Therefore, the reinforcement 33 allows for more precise steering.

Still according to the exemplary embodiment, the reinforcement 33 includes a lower extension 37, 38, 39 extending the arch 35 towards the outer sole assembly 2. The purpose is to increase the yield strength of the stiffener 15, in the area in which the extension extends. Thus, the reinforcement 33 for example includes a lateral lug 37, a rear lug 38, and a medial lug 39, the lateral 37, rear 38, and medial 39 lugs extending the arch 35 towards the outer sole assembly 2. Consequently, the increase in the mechanical strength of the stiffener 15 is distributed at its periphery, namely, in the area of the lateral wall 17, rear wall 19, and medial wall 21. This arrangement makes the influence of the reinforcement 33 on the stiffener 15 uniform, in the sense that it is distributed fairly evenly, and not localized. Therefore, the heel of the foot is held evenly.

To facilitate its positioning on the reinforcement 33, the stiffener 15 has a lateral groove 41 in which the lateral lug 37 is inserted, a rear groove 42 in which the rear lug 38 is inserted, and a medial groove 43 in which the medial lug 39 is inserted. In fact, the lugs 37, 38, 39 of the reinforcement 33 nest into the grooves 41, 42, 43 of the stiffener 15 in order to better affix one to the other. Indeed, this arrangement increases the holding of the reinforcement 33 on the stiffener 15, by wedging the lugs into the grooves. Generally, the stiffener 15 has at least one recess 41, 42, 43 adapted to receive the reinforcement 33.

According to the exemplary embodiment, at least one lug 37, 38, 39 extends from the arch 35 to the sole assembly 2. In fact, here, the three lugs extend from the arch 35 to the sole assembly 2. This arrangement enables a more precise transmission of forces or sensory information transmitted in the area of the stiffener 15, height-wise of the boot.

The reinforcement 33 includes an upper lateral extension 44 and an upper medial extension 45, the extensions 44, 45 running along the flexible envelope 4 of the upper 3 towards the upper end 9. The extensions 44, 45 serve to limit the transverse inclinations of the upper 3 in the area of the user's ankle. This results in better protection against injuries, which are sometimes caused by excessive twisting or inclination of the lower leg in relation to the foot.

Here, the boot 1 includes a collar 48 reversibly connected to the reinforcement 33 by an fastening mechanism 49. The collar 48 extends the extensions 44, 45 towards the upper end 9, and thereby substantially limits, or even prevents, the transverse inclinations of the upper 3 in the area of the lower leg of the user. In other words, the upper portion 12 only slightly inclines transversely, if at all, in relation to the lower portion. This makes the boot 1 well-suited to skiing using the technique of the skating steps, i.e., skate-skiing, due to the transverse holding of the lower leg.

According to the proposed embodiment, the fastening mechanism 49 is an articulation which, by way of example, includes a lateral portion 50 and a medial portion 51. These portions are pivots, made using any known technique. This articulation is dismountable, or removable, in order to provide the boot with greater versatility and greater ease of use. As a result, the collar 48 can be separated from the reinforcement 33, and therefore from the remainder of the boot, or can be repositioned. Consequently, the user can adjust the transverse rigidity of the boot, depending upon whether or not he/she uses the collar 48.

To save time during disassembly or reassembly of the collar 48 from/on the reinforcement 33, the invention provides that the articulation can be disassembled and/or reassembled without tools.

It is notable that the articulation 49 of the collar 48 in relation to the reinforcement 33 occurs along a transverse axis W of the boot. This facilitates the inclinations of the collar 48, and of the upper portion 12 along the length of the boot. Therefore, the lower leg can flex more easily in relation to the foot.

In general, the stiffener 15 is provided to extend from the rear end 5 of the boot 1 to the front end 6, so that the front ends 25, 27 of the lateral 17 and medial 21 walls are located at a distance d between 40 and 65% of the length of the sole assembly 2, the distance d being measured from the rear end 5 of the boot. The value of the distance d can be equal or different for the lateral 17 and medial 21 walls of the stiffener 15. This range of dimensions makes it possible to adjust the compromise between the rigidity of the upper in the area of the rear end 5, for good holding of the heel of the foot, and the ability of the upper to flex towards the front end, for good foot rolling movement.

Although the boot 1 of the invention, as a whole, is manufactured from materials and using techniques of implementation known to one with ordinary skill in the art, it calls for one or more specific operations.

Thus, for the manufacture of the boot 1, a reference step of the method is to mold the heel stiffener 15 using of a mold comprising a base having a shape, called the core, which demarcates the inner surface 55 of the stiffener 15, as well as a first cover, called the shell, which demarcates the outer surface 56 of the stiffener 15; and a step following the reference step involves molding the reinforcement 33 in contact with the stiffener 15, using a mold comprising the base or core which carries the stiffener 15, as well as a second cover or shell substituted for the first, the second cover leaving space to add the reinforcement 33. Therefore, a smaller number of elements is required to mold the reinforcement 33 on the stiffener 15. This makes it possible to save money and time.

For example, injection molding of the stiffener 15, and then the reinforcement 33, with materials selected to enable one to adhere on the other, can be provided. This can be polyurethane, polyamide, or any equivalent material, for example.

Broadly, the invention uses a modular method for manufacturing a boot 1, which comprises a sole assembly 2 and an upper 3, the upper 3 including a flexible envelope 4, the boot 1 including a stiffener 15. The stiffener 15 is adapted to receive various complementary reinforcements 33 having a size and/or stiffness adapted specifically to a particular use of the boot.

The invention is not limited to the embodiment described hereinabove, and includes all technical equivalents that fall within the scope of the claims that follow.

For example, the stiffener can be provided to partially cover the reinforcement.

In addition to the foregoing, the invention disclosed herein by way of exemplary embodiments suitably may be practiced in the absence of any element or structure which is not specifically disclosed herein. 

1. An article of footwear comprising: a sole assembly; an upper comprising a flexible envelope; the article of footwear extending lengthwise from a rear end to a front end, widthwise between a lateral side and a medial side, and height-wise from the sole assembly to an upper end; a stiffener located in an area of the rear end; a reinforcement at least partially superimposed onto the stiffener.
 2. An article of footwear according to claim 1, wherein: the reinforcement comprises an arch extending along the lateral side, the rear end, and the medial side, in the area of an upper end of the stiffener.
 3. An article of footwear according to claim 2, wherein: the reinforcement comprises a lower extension extending the arch towards the sole assembly.
 4. An article of footwear according to claim 2, wherein: the reinforcement comprises a lateral lug, a rear lug, and a medial lug, the lateral, rear, and medial lugs extending the arch towards the sole assembly.
 5. An article of footwear according to claim 1, wherein: the stiffener has at least one recess structured and arranged to receive the reinforcement.
 6. An article of footwear according to claim 4, wherein: the stiffener comprises: a lateral groove in which the lateral lug is inserted; a rear groove in which the rear lug is inserted; a medial groove in which the medial lug is inserted.
 7. An article of footwear according to claim 4, wherein: one of the lugs extends from the arch to the sole assembly.
 8. An article of footwear according to claim 1, wherein: the reinforcement partially covers the stiffener.
 9. An article of footwear according to claim 1, wherein: the stiffener is comprised of a molded synthetic material; the reinforcement is comprised of a molded synthetic material.
 10. An article of footwear according to claim 1, wherein: the reinforcement extends towards the upper end of the article of footwear, beyond an upper end of the stiffener.
 11. An article of footwear according to claim 1, wherein: the reinforcement comprises an upper lateral extension and an upper medial extension.
 12. An article of footwear according to claim 1, further comprising: a collar connected to the reinforcement by a fastening mechanism.
 13. An article of footwear according to claim 12, wherein: the fastening mechanism is an articulation.
 14. An article of footwear according to claim 13, wherein: the articulation of the collar in relation to the reinforcement extends along a transverse axis of the article of footwear.
 15. An article of footwear according to claim 1, wherein: the stiffener extends from the rear end of the article of footwear towards the front end, so that front ends of lateral and medial walls of the stiffener are located at a distance between 40 and 65% of the length of the sole assembly, the distance (d) being measured from the rear end of the article of footwear.
 16. A modular method for manufacturing an article of footwear from a plurality of components, said plurality of components comprising: a sole assembly; an upper having a flexible envelope and a stiffener; a plurality of reinforcements, each of the plurality of reinforcements being structurally complementary with the stiffener for being assembled to the stiffener, and each of the plurality of reinforcements having a respective different size and/or shape; the method comprising: assembling one of the plurality of reinforcements having a size and/or shape specifically adapted to a particular use of the article of footwear.
 17. A method for manufacturing an article of footwear comprising a sole assembly and an upper, the upper comprising a flexible envelope, the article of footwear comprising a stiffener, the method comprising, in the following sequence: molding the stiffener using a mold comprising a base having a shape demarcating an inner surface of the stiffener, as well as a first cover demarcating an outer surface of the stiffener; molding a reinforcement in contact with the stiffener using a mold comprising the base carrying the stiffener, as well as a second cover substituted for the first cover, the second cover leaving space to add the reinforcement. 